Building construction

ABSTRACT

A prefabricated building particularly adaptable for low cost housing includes a core section which comprises a unitary one piece living unit having an opening on at least one side with a lip around the opening. A first module which comprises a partial living unit is disposed next to the core and includes a like opening having a peripheral lip juxtaposed to the core lip with a compression band being disposed around both lips to secure the module and core together. A complementary module is secured to the first module to form the remainder of its living unit.

Elnited States Patent Dalgliesh, Jr. et al.

[ 1 Sept. 12, 1972 [54] BUILDING CONSTRUCTION [72] Inventors: John D. Dalgliesh, Jr., P.O. Box 47, Free Union, Va. 22940; Clinton E. Kisner, Rt. 4, Box 163, Charlottesville, Va. 22202 [22] Filed: March 4, 1970 [21] Appl. No.1 16,463

[52] US. Cl. ..52/79, 52/309, 52/584 [51] Int. Cl ..E04b l/348, E04b 1/40 [58] Field of Search ..52/79, 236, 584, 582, 127, 52/309 [56] References Cited UNITED STATES PATENTS 2,705,349 4/1955 Shaw ..52/584 X 2,969,589 1/1961 Fromson ..52/584 X 2,691,291 10/1954 Henderson ..52/236 3,138,124 6/1964 Baier ..52/169 X 3,331,170 7/1967 Lowe et a1. ..52/79 X 3,363,370 l/1968 Camoletti et a1. ..52/236 X 3,438,157 4/1969 La Monica ..52/79 X 3,527,002 9/ l 970 Mead ..52/79 Primary Examiner-Price C. Faw, Jr. Attorney-Connolly and l-lutz [57] ABSTRACT A prefabricated building particularly adaptable for low cost housing includes a core section which comprises a unitary one piece living unit having an opening on at least one side with a lip around the opening. A first module which comprises a partial living unit is disposednext to the core and includes a like opening having a peripheral lip juxtaposed to the core lip with a compression band being disposed around both lips to secure the module and core together. A complementary module is secured to the first module to form the remainder of its living unit.

5 Claims, 11 Drawing Figures PATENTEDSEP 12 I972 SHEET 1 [1F 7 PAWNYEBsEP 1 2 i972 3690' 077 sum 2 nr- 7 M w a m U OO oo ENTRY :i Eta;- Z M KITCHEN mums PATENFEBSEP 12 I972 SHEET 7 [IF 7 BUILDING CONSTRUCTION BACKGROUND OF INVENTION The recent population explosion has placed an overwhelming demand for new housing units. Construction costs, however, have caused the completion of such housing units to fall behind the increasing population. There is, therefore, a poignant need for low cost housing which could be constructed quickly and conveniently. Various attempts have been made with limited success to answer this need by the provision for example of prefabricated housing units or mobile homes. The key to a successful attack of the problem appears to lie in the utilization of mass production and in the utilization of readily available economically feasible materials without sacrifice to quality.

The mobile home approach at satisfying housing needs while having some advantages has not proven completely satisfactory since these homes are generally of a single level and thus require adequate land area in the mobile home park. The solution therefore appears to reside in an economical prefabricated building which is selectively capable of multi-level construction.

SUMMARY OF INVENTION An object of this invention is to provide a system of prefabricated housing units which can be mass produced and easily transported at low cost.

A further object of this invention is to provide such building construction which provides flexibility of floor plan and unit function.

A still further object of this invention is to provide such building construction which includes a minimal number of components but which maximizes the variety of room volumes, configurations and functions.

In accordance with this invention a prefabricated building particularly adaptable for low cost housing includes a core section which comprises a unitary one piece living unit having an opening on at least one side with a lip around the opening. A first module which comprises a partial living unit is disposed adjacent the core and includes a like opening having a peripheral lip juxtaposed the core lip with a compression band being disposed around both lips to secure the module and core together. A complementary module is secured to the first module to form the remainder of its living unit.

The building construction may include a novel adapter frame which fits in the openings of the living units to provide reinforcement and support thereto. The adapter frame also permits communication between hollow floor inserts of adjoining units.

The building construction may also include a novel carriage which is disposed between vertically arranged living units for providing support thereto and for securing the units together.

THE DRAWINGS FIG. 1 is a front elevation view of a building construction in accordance with this invention;

FIG. 2 is a plan view of possible room arrangements for a building construction in accordance with this invention;

FIG. 3 is an exploded view of various components for the building construction in accordance with this invention;

FIG. 4 is a cross-sectional plan view showing a portion of the building construction in accordance with this invention;

FIG. 5 is a cross-sectional elevation view showing a further portion of building construction in accordance with this invention;

FIGS. 6 and 7 are side and end elevation views partly in section of a portion of building construction in accordance with this invention;

FIG. 8 is an enlarged cross-sectional view illustrating the method of attaching adjoining living units in accordance with this invention;

FIG.. 9 is a side elevation view illustrating the stacking of modules in accordance with this inventionj FIG. 10 is a front elevation view showing a modified form of multi-level construction in accordance with this invention; and

FIG. 11 is a perspective view partly in section of a portion of the building construction shown in FIG. 10.

DETAILED DESCRIPTION FIG. 1 shows a building construction 10 in accordance with this invention. A particular advantage of this construction is that the major components are made of a plastic material which is particularly effective in its insulation, weatherability, glazing, etc., properties. The building construction includes a plurality of individual living units which are formed by core units 12 or by complementary modules 14, 16. The living units formed by the modules can be varied in size by the use of inserts 18.

The core units handle all vertical circulation and mechanical shafts thus permitting the modules to be formed in as simple manner as possible. Accordingly, as illustrated for example in FIG. 9, the individual modules may be easily stacked to reduce bulk in transportation and may be light weight for easy handling, hoisting and assemblage. Suitable plastic materials, which are later referred to in greater detail, for the core unit and modules add to the light weight nature and low cost of these components.

Since the core unit is particularly designed to handle the service and utility equipment (e.g. v wiring and plumbing) baths, kitchens'and similar equipment are disposed directly adjacent to the core unit 12 for direct mechanical installation. As shown for example in FIG. 3 the core unit includes openings 20 in all walls with circular openings 22, 24 in the top and bottom as well as vertical shafts or chambers 26 disposed in the corners of the core unit. The four side openings provide access to adjacent modules as well as the ability to install various inserts such as doors, windows, shelfs, kitchen components, etc. The openings are supported by adapter frames 28 which also provide interior finish The details of the lip and band construction are more clearly shown in FIG. 8. As illustrated therein each lip 30 includes an offset shoulder 33 thereby creating a recess 34. Each lip further includes a vertical wall 36. Preferably a gasket 38 is inserted between adjacent lips before insertion and tightening of band 32 to render the joint weather and moisture proof. The type of joint illustrated in FIG. 8 is utilized throughout the system for joining pairs of components. Band 32 which as illustrated in FIG. 8 is of U-shaped cross-sectional construction includes a pair of reinforcing elements 40 which snap into the recesses 34. Any suitable tighten ing means such as the toggle clamp 42 (as illustrated in FIG. 3) is utilized to secure the band in place.

The living units are supported on carriages or cradles 44 as illustrated for example in FIG. 1 and described in greater detail hereinafter. These carriages are made of a suitable supporting material such as aluminum and act as beams which, as later described, may be held in place by either tension cables or columns. Since the living unit formed by the core, per se, or the modules, per sc, is essentially a bulged out box, a finished appearance and functionality is achieved by the use of adapter frames 28 and also by floor inserts 46 and 48. A full insert 46 is disposed in the core unit while a pair of half floor inserts are arranged in the module living unit and are disposed transverse to the direction of the individual complementary modules. The floor inserts which advantageously are of acrylic foam are hollow in that they incorporate a grid of voids to handle all mechanical ducts and pipes. If desired the ducts may be made of plastic suspended in foam. The supply and return ducts are located in the floor inserts and pass from unit to unit through openings provided in the bottom of the adapter frames. These service and utility ducts or conduits may then pass vertically through the chambers 26 provided in the core units.

The entire system may be pre-wired by a grid of uninsulated wires located directly under the acrylic layer. This can be done since the contemplated plastic material provides better electrical insulation than standard electric cable. Using the same principle radiant electric heat can be practically installed. In connecting various units conventional male and female plugs are joined together to connect the electrical, heating and cooling ducts, and plumbing. In a high rise construction the core units may have their mechanical and electrical plugs attached to pedestrian walks which, similar to the floor inserts, may have a grid of voids permitting ducts and piping to be disposed under the walk surface.

FIGS. 3 and 4 illustrate a typical core unit 12. As shown therein the core unit includes outwardly bulging sides and an outwardly bulging roof and bottom with the core comprising a unitary one piece living unit. Openings are provided in each of the sides while openings 22, 24 are provided in the roof and bottom. Each of the openings includes a peripheral lip 30 while vertical chambers 26 are disposed in each corner for housing service or utility conduits 50. As illustrated in FIG. 1 suitable caps 51 cover the openings at the top of chambers 26 in the uppermost core unit. For a multilevel unit each chamber 26 communicates with a like chamber above and/or below it. The floor insert 46 includes a tapered opening 52 which communicates with opening 24 in the bottom of core 12. A spiral staircase unit 54 is provided having a floor section 56 which plugs into opening 52 as shown for example in FIG. 5. A bottom cap 58 is disposed beneath the staircase and has a lip 30 for securement to core 12. The uppermost core unit is similarly sealed with an upper cap 60. If desired a well-light may be provided for cap 60.

The spiral staircase extends through the opening 22 at the roof of core 12. The provision of such spiral staircases allows the units to stack vertically with the core unit becoming the focal point of the floor plan since it is the center of both circulation and mechanical services. If desired more than one core may be on the same level to permit separation of active functions (such as kitchen, living and dining room) and quiet functions (such as sleeping, bathing and studying). The individual living units may be reduced in volume by inserting prefabricated structures such as storage modules, bathrooms or kitchen units or the living units may be partitioned by the provision of sliding panels. The core unit is particularly adaptable for use as the entrance to the structure. Thus as shown for example in FIG. 1 one of the side openings in the core unit would be provided with the end wall surface having a door 62 and steps 64.

The additional living units are made by complementary modules. When a pair of such modules 14, 16 are fit together they have similar construction to a single core unit 12 in that the resultant living unit would be open at four sides. The floor and roof of the resultant units, however, would not have openings as in the case of the core units. Modules 14 and 16 are connected together by an I-I-shaped seal 66 which is illustrated in FIG. 7. As previously noted the living units formed by the modules may be varied by the inserts 18 at the top and bottom thereof. In such case larger floor inserts and adapter frames would also be provided.

In general the floor inserts 46, 48 have a flat upper surface which serves as the working floor for a living unit while the bottom surface of the insert conforms to the floor of the core or complementary modules. A plurality of posts 68 provide sufficient strength and rigidity to the floor insert and create a hollow grid framework which permits piping and electrical wiring to be placed therein. The floor inserts of adjacent living units communicate with each other through openings in the adapter frames.

The adapter frame 28 utilized with this invention is also particularly noteworthy. As shown for example in FIGS. 3 and 6-8 adapter frame 28 includes an outer edge 70 which seats against the inner edge of an opening 20 in a living unit. A peripheral flange 74 extends completely around the outer edge 70 and conforms to the wall of the opening so that the frame contacts the opening around two surfaces. The outer edge is generally flat in cross section. The inner edge 76 is spaced from outer edge 70, with edge 76 forming a rectangular rim to provide a finished appearance to each opening. This rim is hollow as indicated at 78 in FIG. 8 thus rendering the frame light weight and providing a certain degree of resiliency thereto. As shown for example in FIGS. 7 and 11 the bottom portion of the adapter frame rim includes vertical posts 80 and the hollow frame is exposed for communication with the hollow interiors of the floor inserts thus enabling piping and electrical wiring 50 to extend from unit to unit as illustrated for example in FIGS. 5 and 1 1. As further shown in FIG. 8 the hollow adapter frames in the pair of adjacent openings are disposed against each other and secured together in any suitable manner by for example toggle clamps similar to compression band 32 or, as illustrated in FIG. 8, the bolts 82.

The exposed openings in the various living units are closed by extended end walls 84 which are illustrated in FIGS. 3 and 6-7. The end wall structure is of double layer construction and includes a first layer 86 disposed against frame 28 and conforming to the rectangular rim formed by frame 28. A second layer 88 is peripherally connected to layer 86 and otherwise spaced therefrom. A peripheral lip 30 is provided on layer 88 so that the extended end wall and living unit may be secured together. The glazed extended end wall may be made transparent or slightly tinted to function as a picture window or be made of varying degree of opaqueness where more privacy is desired. A particularly suitable material for the end wall 84 which as illustrated in the drawings gives a bubble appearance, is a Lucite material, although other suitable materials may be used.

Another advantageous component of the building structure 10 is the carriage or cradle 44. As illustrated in FIGS. 1, 6, 7 and 11 carriage 44 is generally of X- shape for seating against the floor of one living unit and the roof of another unit. In certain instances, of course, as shown in FIG. 1 where carriage 44 supports the lowermost level of living units the lower portion of the X does not seat against any living unit. As particularly shown in FIGS. 6 and 11 the upper (and also lower) edge of each carriage includes a central ledge 92 with a shoulder 94 disposed on each side thereof. The compression band of the adjacent living unit is seated against ledge 92 while a lip lock or band 96 rests on each shoulder and extends a sufficient amount to abut against compression band 32. The lip locks 96 may be secured together in any suitable manner as for example by bolts.

The remote ends of the carriage X are connected by vertical posts 90. Each vertical post 90 is provided with a series of vertical passages or grooves 98 extending completely therethrough with tension cables 100 being inserted in the passages (FIG. 11). Cable clamps 102 assure the maintenance of the cables 100 in the grooves or passages 98. Each carriage thus acts as a beam which is held in place by the tension cables and in turn supports and holds in place each living unit. Alternatively the carriages are held in place by posts 90 being mounted on and secured to vertical columns 101 (FIG. 1).

FIG 10 shows one arrangement wherein a high rise office, apartment or other structure is made in accordance with this invention. As indicated therein a horizontal truss 103 is mounted on vertical columns 106 which are supported on the ground level in any suitable conventional manner. Cables 100 are suspended from the truss 103 so that a plurality of the living units would be mounted together to create a high rise structure. Advantageously the columns 106 may be made hollow to provide an entranceway and elevator shaft for the high rise structure.

As previously indicated a particularly suitable material for the major components of the building structure such as the core and complementary modules is a plastic laminate which can be injection molded. Lucite (registered trademark of Du Pont Co.) is particularly useful with this invention since it is a light weight plastic having about one-half the weight of glass and possessing high tensile strength and relatively high strength over a wide temperature range. Moreover, this acrylic resin is a good thermal insulator and has good resistance to thermal flow. A detailed discussion of the advantages of this material and of the methodology of assembly are found in a thesis entitled The Plastic House submitted by applicants to the University of Virginia in May 1969, the details of which are incorporated herein by reference thereto.

As can be appreciated with the building structure 10 described in this application, it is possible to prefabricate single dwellings or high rise units. A particular advantage of this construction is that living units may be added or subtracted in accordance with changing needs since each of the components is readily detachable. Thus, for example, if an additional room is required an extended end wall may be removed and a set of complementary modules may be inserted in its place. Conversely if through changing circumstances it is desired to remove a room the compression band may be detached and a unit then substracted with any openings created thereby closed by extended end walls.

What is claimed is:

l. A building construction comprising a core, said core being a unitary one piece living unit, an enlarged opening in at least one of the side walls of said core, a peripheral lip around said opening, a first module, said first module being a partial living unit, said first module having an enlarged opening in its side wall, said module being disposed against said core with their openings in communication with each other, a peripheral lip around the opening of said module and disposed juxtaposed to said lip on said core opening, a compression band around said lips, tightening means on said compression band causing said lips to press against each other for securing said core and module together, a complementary module disposed against said first module to comprise the remainder of the living unit, and securing means securing said first and complementary modules together.

2. A building construction as set forth in claim 1 wherein said core includes an enlarged opening in each of its four sides with a peripheral lip around each opening, a floor insert disposed in each living unit for creating a planar surface therein, and means cooperating with each of said lips for closing each of said openings.

3. A building construction as set forth in claim 2 wherein the floor insert for each living unit created by said modules includes a pair of half floor sections, and each half floor section extending across its pair of modules.

4. A core for use in a building structure, said core comprising a unitary one piece living unit made of an injection molded plastic material, the sides and the roof and the floor of said core bulging outwardly, an enlarged opening in each of the sides of said core, a central opening in said roof, a central opening in said floor disposed under said central opening in said roof, a peripheral lip around each enlarged opening and each central opening, each lip having a generally peripheral wall disposed remote from the core interior for being disposed against a complementary wall on an adjacent module, each lip further having a peripheral outer wall connected to said generally vertical wall adapted to be disposed against a similar wall on the lip of an adjacent module whereby one surface of a compression band may be disposed against said outer wall and the outer wall of the lip on the adjacent module, said lip further having a peripheral shoulder remote from said generally vertical wall and creating a peripheral recess under said shoulder for accommodating a further surface of a compression band, and vertical chambers in the corners of said core extending from below said bottom to above said roof.

5. A module for use in a building structure, said module being a partial living unit, said module including one complete side wall with an enlarged opening therein, said module further including partial roof and floor sections and partial side wall sections each of which is adapted to form a completed section when juxtaposed a like section in a second mirror-image module, enlarged openings in each of said partial wall sections adapted for communication with similar openings in the mirror-image modules, said side wall and said partial roof, floor and wall sections bulging outwardly, in combination therewith, a second mirrorimage module, a roof insert between the partial roof sections of the first and second modules, side inserts between the partial side wall sections of the first and second modules, a floor insert between the partial floor sections of the first and second modules, each module being made of an injection molded material, a lip section on each abutting modules and inserts with the lip sections forming a continuous lip, and a compression band around said continuous lip pressing said lip sections together to comprise securing means for said modules and inserts. 

1. A building construction comprising a core, said core being a unitary one piece living unit, an enlarged opening in at least one of the side walls of said core, a peripheral lip around said opening, a first module, said first module being a partial living unit, said first module having an enlarged opening in its side wall, said module being disposed against said core with their openings in communication with each other, a peripheral lip around the opening of said module and disposed juxtaposed to said lip on said core opening, a compression band around said lips, tightening means on said compression band causing said lips to press againSt each other for securing said core and module together, a complementary module disposed against said first module to comprise the remainder of the living unit, and securing means securing said first and complementary modules together.
 2. A building construction as set forth in claim 1 wherein said core includes an enlarged opening in each of its four sides with a peripheral lip around each opening, a floor insert disposed in each living unit for creating a planar surface therein, and means cooperating with each of said lips for closing each of said openings.
 3. A building construction as set forth in claim 2 wherein the floor insert for each living unit created by said modules includes a pair of half floor sections, and each half floor section extending across its pair of modules.
 4. A core for use in a building structure, said core comprising a unitary one piece living unit made of an injection molded plastic material, the sides and the roof and the floor of said core bulging outwardly, an enlarged opening in each of the sides of said core, a central opening in said roof, a central opening in said floor disposed under said central opening in said roof, a peripheral lip around each enlarged opening and each central opening, each lip having a generally peripheral wall disposed remote from the core interior for being disposed against a complementary wall on an adjacent module, each lip further having a peripheral outer wall connected to said generally vertical wall adapted to be disposed against a similar wall on the lip of an adjacent module whereby one surface of a compression band may be disposed against said outer wall and the outer wall of the lip on the adjacent module, said lip further having a peripheral shoulder remote from said generally vertical wall and creating a peripheral recess under said shoulder for accommodating a further surface of a compression band, and vertical chambers in the corners of said core extending from below said bottom to above said roof.
 5. A module for use in a building structure, said module being a partial living unit, said module including one complete side wall with an enlarged opening therein, said module further including partial roof and floor sections and partial side wall sections each of which is adapted to form a completed section when juxtaposed a like section in a second mirror-image module, enlarged openings in each of said partial wall sections adapted for communication with similar openings in the mirror-image modules, said side wall and said partial roof, floor and wall sections bulging outwardly, in combination therewith, a second mirror-image module, a roof insert between the partial roof sections of the first and second modules, side inserts between the partial side wall sections of the first and second modules, a floor insert between the partial floor sections of the first and second modules, each module being made of an injection molded material, a lip section on each abutting modules and inserts with the lip sections forming a continuous lip, and a compression band around said continuous lip pressing said lip sections together to comprise securing means for said modules and inserts. 